Monitoring system, control system, and actuation assembly of a paper machine, and a method of controlling

ABSTRACT

A monitoring system comprising: (a) one or more sensors that monitor activity, amplitude, size, scale, duration of activity or a combination thereof of stock on a paper machine and (b) a control system in communication with the one or more sensors and one or more foil sections within the paper machine; wherein the control system measures the activity, amplitude, size, scale, duration of activity or a combination thereof of the stock and correlates the activity, amplitude, size, scale, duration of activity or a combination thereof to formation of fibers within the stock so that an angle, height, or both of the one or more foil sections are adjusted to change the activity, amplitude, size, scale, duration of activity or a combination thereof in the stock.

FIELD

The present teachings relate to a monitoring system that is connected toa control system for actuating one or more components of a paper machinesuch as blades (e.g., foils), vacuum levels, slice opening, jet to wireratios, activity showers, or a combination thereof on a paper machinebased upon a detected condition, and a method of controlling the papermachine.

BACKGROUND

Typically, fourdrinier paper machines include a wet end with a wire thatmoves in a machine direction. The wire has a width (i.e., cross-machinedirection) and stock is applied substantially along the entire width ofthe wire. A plurality of blades are located under the wire and theplurality of blades assist in removing water from the stock on the wire.The blades are typically static, however, more recently foils and bladesthat actuate have been added to the wet end. A deckle may be used onboth edges of the wire to retain substantially all of the stock on thewire. Deckle boards are used to create an edge on a paper machine and toretain stock, water, fines, filler, or a combination thereof on the wireof the paper machine. Typically, changes to the paper machine are madeby a user adjusting machine characteristics such as a slice opening ormachine speed based upon dry end test results. Thus, there is a delaybetween testing dry end paper and making machine adjustments at the wetend of the paper machine, causing additional waste product, out ofspecification product, or increasing a duration of a grade change.

Examples of monitoring and adjustment devices for paper machines aredisclosed in U.S. Pat. Nos. 5,239,376; 5,472,571; 5,492,601; 8,551,293;9,045,859; International Patent Application Publication No.WO2003/081219 all of which are expressly incorporated herein byreference for all purposes. Thus, there is a need for a device thatmonitors activity, amplitude, scale, duration of changes, tableactivity, or a combination thereof. What is needed is a device thatmonitors and saves activity amplitude, scale, the duration of changes,or a combination thereof and at a later date resets the paper machine toduplicate the saved activity amplitude, scale, the duration of changes,table activity, or a combination thereof. What is needed is a monitoringsystem that monitors the wet end and allows for real time changes to bemade without waiting for dry end testing data. What is needed is amonitoring system that measures an amplitude of activity and scale. Whatis needed is a monitoring system that is located substantially overheadof the paper machine and monitors the cross-machine direction of thepaper machine as the stock travels under the monitoring system.

SUMMARY

One possible embodiment of the present teachings provide: a monitoringsystem comprising: (a) one or more sensors that monitor activityamplitude, scale, duration of activity or a combination thereof of stockon a paper machine and (b) a control system in communication with theone or more sensors and one or more foil sections within the papermachine; wherein the control system measures the activity, amplitude,scale, duration of activity or a combination thereof of the stock andcorrelates the activity, amplitude, scale, duration of activity or acombination thereof to formation of fibers within the stock so that anangle, height, or both of the one or more foil sections are adjusted tochange the activity, amplitude, scale, duration of activity or acombination thereof in the stock.

The present teachings provide: (a) a control system comprising: acontroller; (b) a transmitter; and (c) one or more communication devicesthat receive signals from a monitoring system that monitors one or morelocations of a paper machine; wherein the one or more communicationdevices receive the signals from the monitoring system and send thesignals to the controller where the controller compares an activity,amplitude, size, scale, duration of activity, or a combination thereofto an activity change; and wherein the transmitter transmits a controlsignal from the controller to one or more foils, blades, vacuum, sliceopenings, jet to wire rations, or a combination thereof of a papermachine.

The present teachings provide: a method comprising: (a) monitoring oneor more regions of a paper machine to obtain current activity, currentamplitude, current size, current scale, current duration of activity, ora combination thereof of the one or more regions; and (b) comparing thecurrent activity, the current amplitude, current size, current scale,current duration of activity, or a combination thereof to a referenceactivity, a reference amplitude, reference size, reference scale,reference duration of activity, or a combination thereof respectively todetermine a difference in activity, a difference in amplitude, adifference in size, a difference in scale, a difference in duration ofactivity, or a combination thereof of the one or more regions.

The present teachings provide: a monitoring system comprising: (a) oneor more sensors that monitor activity of stock on a paper machine and(b) a control system in communication with the one or more sensors andone or more foil sections within the paper machine; wherein the controlsystem measures the activity of the stock and correlates the activity toformation of fibers within the stock so that an angle, height, or bothof the one or more foil sections are adjusted to change the activity ofthe stock.

A control system comprising: (a) a controller; (b) a transmitter; and(c) one or more communication devices that receive signals from amonitoring system that monitors one or more locations of a papermachine; wherein the one or more communication devices receive thesignals from the monitoring system and send the signals to thecontroller where the controller compares an activity to an activitychange; and wherein the transmitter transmits a control signal from thecontroller to one or more foils of a paper machine.

A method comprising: (a) monitoring one or more regions of a papermachine to obtain current activity of the one or more regions; and (b)comparing the current activity to a reference activity respectively todetermine a difference in activity of the one or more regions.

The present teachings provide a device that monitors and saves activity,scale, amplitude, duration of changes, table activity, or a combinationthereof and at a later date resets the paper machine to duplicate thesaved activity, scale, amplitude, duration of changes, or a combinationthereof. The present teachings provide a monitoring system that monitorsthe wet end and allows for real time changes to be made without waitingfor dry end testing data. The present teachings provide a monitoringsystem that monitors an amplitude of activity and scale. The presentteachings provide a monitoring system that is located substantiallyoverhead of the paper machine and monitors the cross-machine directionof the paper machine as the stock travels under the monitoring system.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a wet end of a paper machine;

FIG. 1B is a top view of a cross-section of the paper machine;

FIG. 1C is a side view of FIG. 1B along lines 1C-1C;

FIG. 1D is a side view of a wet end of a paper machine including amonitoring system;

FIG. 2A is an image from a low angle sensor before a system change;

FIG. 2B is an image from a low angle sensor after a system change;

FIG. 3A is an image from a low angle sensor before a system change;

FIG. 3B is an image from a low angle sensor after a system change;

FIG. 4 is the image from 3B with an activity line indicating the amountof activity change and real-time analysis of highlighted activity overthe activity line;

FIG. 5 is a simulation of stock activity pulsations;

FIG. 6 illustrates a high angle sensor on the paper machine;

FIG. 7A is an image from a high angle sensor before a system change;

FIG. 7B is an image from a high angle sensor after a system change;

FIG. 8A is a reference image generated from a high angle sensor beforeengagement of a portion of the dewatering system;

FIG. 8B is an image from a high angle sensor after a system change withthe image being divided into monitoring regions;

FIG. 9 illustrates an activity measurement of each monitoring region;

FIG. 10A illustrates a control flow chart;

FIG. 10B illustrates a control flow chart;

FIG. 11 illustrates a cut through and a side view of a head box and wetend of a paper machine;

FIG. 12 is a side view of a head box and wet end of a paper machine anda relative spacing of the paper machine components;

FIG. 13 is a perspective view of a dry line, wet line, and activityline;

FIG. 14A illustrates a section of blades adjusted to have a low stockactivity;

FIG. 14B illustrates a section of blades adjusted to have anintermediate stock activity;

FIG. 14C illustrates a section of blades adjusted to have a high stockactivity;

FIG. 14D is a side view of a section including both height adjustableblades and angle adjustable blades;

FIG. 15A illustrates a section of blades adjusted to have a low stockactivity;

FIG. 15B illustrates a section of blades adjusted to have a high stockactivity;

FIG. 15C is a side view of a section including both height adjustableblades and static blades;

FIG. 16A illustrates a section of blades adjusted to have a low stockactivity;

FIG. 16B illustrates a section of blades adjusted to have high stockactivity;

FIG. 16C is a side view of a section including both angle adjustable andstatic blades;

FIG. 17A is a screen shot from a camera showing stock activity;

FIG. 17B is a screen shot from a camera showing stock activity;

FIG. 17C is a screen shot from a camera showing stock activity; and

FIG. 17D is a screen shot from a camera showing stock activity.

DETAILED DESCRIPTION

The explanations and illustrations presented herein are intended toacquaint others skilled in the art with the invention, its principles,and its practical application. Those skilled in the art may adapt andapply the invention in its numerous forms, as may be best suited to therequirements of a particular use. Accordingly, the specific embodimentsof the present invention as set forth are not intended as beingexhaustive or limiting of the teachings. The scope of the teachingsshould, therefore, be determined not with reference to the abovedescription, but should instead be determined with reference to theappended claims, along with the full scope of equivalents to which suchclaims are entitled. The disclosures of all articles and references,including patent applications and publications, are incorporated byreference for all purposes. Other combinations are also possible as willbe gleaned from the following claims, which are also hereby incorporatedby reference into this written description.

The present teachings are predicated upon providing an improvedmonitoring system, control system, method, or a combination thereof fora paper machine, and preferably a fourdrinier paper machine. The papermachine may be any paper machine where stock traveling in a machinedirection may be monitored and controlled. The paper machine taughtherein may be any paper machine that functions to create paper. Thepaper machine may be any style and/or type that forms paper. The papermachine includes a head box that applies stock in a wet end.

The head box may be gravity fed, pressurized, or both. The headbox mayapply stock at a speed slower than the speed a wire in the wet end ismoving (e.g., drag mode). The headbox may apply stock at a speed fasterthan the speed a wire in the wet end is moving (e.g., rush mode). Theheadbox may apply stock substantially at the same speed as the wire inthe wet end is moving (e.g., square mode). The head box may function toapply stock to a wet end, above a breast roll, on foils, or acombination thereof. The head box may function to apply stock to a wirewhile the wire passes over a forming board or over a forming section.The head box may apply stock to the wire at a location proximate to abreast roll and a forming board. The head box may have a top portionthat is movable up and down. For example, a static head of fluid may beadjusted by moving a top of the head box up or down, or the amount ofstock applied to the wire may be adjusted by moving a top of the headbox up or down (e.g., adjusting a slice opening. The head box mayinclude one or more slice openings.

The slice opening may function to guide stock from the head box onto thewire. The slice opening may vary a velocity of stock traveling onto awire, a volume of stock onto a wire, an angle of stock approaching awire, or a combination thereof. The slice opening may be adjusted. Theslice opening may have a top portion or a bottom portion that aremovable. The top portion may increase a height or decrease a height of aslice opening. The top portion may pivot so as to change an angle of thestock jet while increasing a distance between the top portion and thebottom portion. The bottom portion may be movable in the machinedirection. The bottom portion may change a distance between the head boxand the forming board. The bottom portion, the top portion, or both maychange an angle of the stock jet relative to the wire, the formingboard, or both. The top portion, the bottom portion, or both may move inthe machine direction (e.g., forward and backward); up and down (e.g.,towards and away from the wire; pivot a portion towards or away from thewire; or a combination thereof. The slice opening may affect a contactlocation, contact angle, stock velocity, or a combination thereof of thestock jet relative to the wire, breast roll, forming board, formingsection, or a combination thereof.

The stock jet functions to place stock on a wire while beginning toimpart certain characteristics into the fibers in the stock. Forexample, if a stock jet is moving slower than a wire (e.g., drag) thefibers may tend to be aligned in the machine direction. In anotherexample, if the stock jet is moving at a same speed as the wire thefibers may tend to be more randomly oriented than when the stock jet isin rush or drag. The stock jet may be substantially parallel to thewire. The stock jet may impinge into the wire. The stock jet may extendout of the slice opening at an angle of about 1 degree or more, about 3degrees or more, about 5 degrees or more, about 7 degrees or more, orabout 10 degrees or more relative to a plane parallel to the wire sothat the stock jet is angled towards the wire. The stock jet may extendout of the slice opening at an angle of about 45 degrees or less, about30 degrees or less, or about 15 degrees or less relative to a planeparallel to the wire so that the stock jet is angled towards the wire.The stock jet may first hit a bottom of the slice opening before beingtransferred to the wire. The stock jet may come out of the slice openingand first contact the wire above the breast roll or the forming board.The stock jet may exit the slice opening and hit the wire between thebreast roll and the forming board or forming section. The angle, contactlocation, speed, velocity, or a combination thereof may be controlleddepending on measured activity on the wire of the paper machine.Depending on the angle, speed, consistency, contact location, or acombination thereof the stock may begin to be dewatered by the wire bywater being forced through the wire.

The wire may be a porous continuous belt that travels between the breastroll and the couch roll and carries stock. The wire may be flexibleenough to be moved and changed by the foils within the various foilsections. The wire may be metal, plastic, a polymer, woven, non-woven,or a combination thereof. The wire may include pores so that water maybe removed from the stock but solids retained. The wet end may have awire that travels in a machine direction with stock and the stock isdewatered as the wire moves in the machine direction. Preferably, thewet end includes an endless wire that travels in a machine direction.The width of the wire may extend in the cross-machine direction. The wetend may have opposing edges that may have stock that runs along across-machine direction and falls off the wire. The wet end may end witha couch roll (i.e., couch roll end) that functions to wrap the wire andguide the wire in a direction opposite the machine direction so that anendless wire is formed. The couch roll may function to dewater. Thecouch roll may include suction. The couch roll may end the wet end. Thecouch roll may assist in guiding a sheet from the wet end into a presssection. The stock may be sufficiently dry when the stock reaches thecouch roll that the stock has paper like qualities and isself-supporting. The stock may be sufficiently self-supporting once adry line is visible in the stock. The dry line may be monitored by amonitoring system. The wire may carry stock from the head box to a presssection.

Stock as discussed herein is a slurry of fibers mixed in water andoptional paper chemicals to enhance certain final paper characteristics.Stock may include fiber, fines, filers, chemicals, virgin fibers,recycled fibers, synthetic fibers, mineral fibers, glass fibers, polymerfibers, or a combination thereof. The stock preferably is at 90 percentor more, 95 percent or more, or even 99 percent or more water at theheadbox (e.g., has a consistency of about 1 percent or less stock and 99percent or more water by weight). As the stock travels in the machinedirection (i.e., a direction of movement from a wet end to a dry end)the foils or blades and groups of foils (e.g., foil sections) or groupsof blades (e.g., blade sections) remove the water and consistency (i.e.,percentage of water in the stock) decreases. Water may continually beremoved from the stock as the stock travels toward the wet end. Thestock at some point will go from being a primarily liquid state to beinga primarily solid state, which is referred to a dry line (i.e., avisible point on the paper machine where the tock goes from dark tolight (typically at a sheet consistency of between about 8 percent toabout 10 percent)).

The dry line functions to indicate that a sheet is formed and the sheetis becoming solid. The water may be removed to a point where a “dryline” is visible. The dry line is a line that forms in the cross-machinedirection (i.e., a direction 90 degrees to the machine direction) wherea sufficient amount of water is removed so that the stock no longerappears glossy or wet. The dry line may be substantially straight. Thedry line may be staggered and the dry line may appear at edges of thepaper machine before the dry line appears in a center of the papermachine. For example, the dry line may appear to have one or morefingers. The dry line may be monitored by one or more sensors. The oneor more sensors may monitor a contrast from a wet side to a dry side ofthe dry line. The one or more sensors may monitor a width of atransition zone from a wet side to a dry side of the dry line. The oneor more sensors may monitor a shape of the dry line, a length of fingersextending form the dry line, a histogram of movement of regions orfingers of the dry line, or a combination thereof. The dry line islocated between the breast roll and the couch roll. The dry line mayoccur after a wet line (i.e., downstream in the machine direction).

The wet line may function to indicate a location on the paper machinewhere a sufficient amount of water is removed so that the stock nolonger reflects light or has a mirrored appearance. The wet line mayoccur at a consistency of between about 5 percent and about 6 percent(i.e., about 5 percent solids and 95 percent water by weight). The wetline may indicate that sheet formation has occurred. The wet line mayindicate that the fibers are immobilized. The wet line may occur afterthe stock activity line.

The stock activity line may function to indicate where turbulence,activity, or both end on the paper machine. The stock activity line maybe located upstream of the wet line and the dry line. The stock activityline may be a line where a sufficient amount of water is removed so thatthe fibers become suspended, the stock begins to solidify, the fibersbegin to lie on the wire, or a combination thereof. The stock activityline may indicate a location where formation has begun and activity mayneed to be reduced or eliminated. The stock activity line may indicate aconsistency of about 2 percent or more, about 3 percent or more, or evenabout 4 percent or more. The stock activity line may indicate aconsistency of about 3 percent to 4 percent. The stock activity line mayoccur after the breast roll, after the first section, after the secondsection, or after the third section but before the wet line, the dryline, or both.

The breast roll may be the first roll of the wet end (i.e., at the headbox end), may assist in formation, may remove water from the stock, or acombination thereof. The breast roll may be the lead roll in a wet end.The breast roll may be located on an opposite end of the wet end as thecouch roll in the machine direction. The couch roll may be a last rollon the wet end of the paper machine. The couch roll may be locatedbetween the wet end and the press sections. The wet end may function toreceive stock and dewater stock. One or more forming boards, formingsections, or both may be located between the breast roll and the foilsections.

A forming section may be located downstream of the breast roll. Theforming section may function to assist in receiving stock from the sliceopening and to assist in configuring the stock so that fibers in thestock are oriented in a desired orienting (e.g., machine direction,cross machine direction, random). The forming section may include one ormore foils, one or more forming boards, or both. The first foil of allof the foil sections may be a forming board. The forming board may bestatic. The forming board may be movable in the machine direction. Theforming board may move so that the distance between the forming boardand the head box is increased or decreased. The forming board may beheight adjustable. The forming board may be angle adjustable. Theforming board may be moved to increase or decrease the amount of waterremoved from the stock jet.

The wet end may be a portion of the paper machine where the paper has aconsistency of about 15 percent or less or about 10 percent or less. Thewet end may be a portion of the paper machine that is located upstreamof a press section. The wet end may receive stock that is primarilywater and remove the water until a sheet is formed. The wet end may haveone or more and preferably a plurality of foil sections (or bladesections). For example, the wet end may have a first section, secondsection, third section, fourth section, or more. The wet end may removewater from stock. The wet end may impart activity into the stock so thatformation of the stock is controlled, formation of a sheet of paper iscontrolled, the fibers are oriented or reoriented, the fibers remainsuspended within water. The wet end may include one or more activityshowers.

The one or more activity showers may function to introduce turbulence,activity, water, chemicals, or a combination thereof into the wet end.The one or more activity showers, may be located in or over a firstsection, a second section, a third section, a fourth section, or acombination thereof. The one or more activity showers may add water,spray water, or create turbulence within the stock that has been placedon the wire so that the stock may be dewatered, reoriented, maintainedin solution, or a combination thereof. The one or more activity showersmay break-up fibers on the wire. The one or more activity showers mayspray a fluid, jet a fluid, drop a fluid, or a combination thereof intothe stock or unto the wire. The activity shower may be controlled by thecontrol system, the monitoring system, or both. The activity shower maybe controlled by changing pressure of the fluid coming out of theactivity shower (e.g., increasing or decreasing); changing a volume offluid coming out of the activity shower (e.g., increasing ordecreasing); changing temperature of the fluid; varying an angle of thefluid coming out of the activity shower relative to the stock; or acombination thereof. If activity is not within a predetermined parameterthen the activity shower may be turned on, turned off, increased,decreased, or some condition therebetween to change the activity withinthe wet end. The wet end may have a plurality of sections of foils orblades.

The first section may function to begin dewatering stock as the stockexits the head box, the slice opening, the forming board, the formingboard section, or a combination thereof. The first section may includestatic foils, height adjustable foils, angle adjustable foils, or acombination thereof. The various foils may be alternating; only static;all height adjustable foils; all angle adjustable foils; heightadjustable foils and angle adjustable foils; height adjustable foils andstatic foils; angle adjustable foils, height adjustable foils, andstatic foils; or a combination thereof. Preferably, the first section isa combination of angle adjustable foils and height adjustable foils; allheight adjustable foils; or all angle adjustable foils. The firstsection may be vacuum assisted. The first section may be free of vacuumassistance. The first section may be located directly upstream of thesecond section.

The second section may function to continue dewatering stock as thestock travels in the machine direction. The second section may dewaterstock that is exiting the first section. The second section may includestatic foils, height adjustable foils, angle adjustable foils, or acombination thereof. The various foils may be alternating; only static;all height adjustable foils; all angle adjustable foils; heightadjustable foils and angle adjustable foils; height adjustable foils andstatic foils; angle adjustable foils, height adjustable foils and staticfoils; or a combination thereof. Preferably, the second section is acombination of static foils and height adjustable foils with vacuumassist. The second section may be vacuum assisted. The second sectionmay be free of vacuum assistance. The second section may be locateddirectly upstream of the third section.

The third section may function to continue dewatering stock as the stocktravels in the machine direction. The third section may dewater stockthat is exiting the second section. The third section may include staticfoils, height adjustable foils, angle adjustable foils, or a combinationthereof. The various foils may be alternating between different types offoils; only static; all height adjustable foils; all angle adjustablefoils; height adjustable foils and angle adjustable foils; heightadjustable foils and static foils; angle adjustable foils, heightadjustable foils, and static foils; or a combination thereof.Preferably, the third section is a combination of static foils on endsand angle adjustable foils located therebetween with the third sectionincluding vacuum assist. The third section may be vacuum assisted. Thethird section may be free of vacuum assistance. The third section may befollowed by a fourth section, a vacuum section, steam boxes, a highvacuum section, or a combination thereof that may include blades orfoils.

Blades and foils as discussed herein may be used interchangeably. Thefoil sections may each include one or more foils and preferably aplurality of foils. The foils may be height adjustable, angleadjustable, fixed, or a combination thereof. The foil sections mayinclude one or more forming boards. The forming boards may be part of aforming board section. The forming board section may include heightadjustable foils, angle adjustable foils, fixed foils, static foils, ora combination thereof. The foils and blades may be adjusted by anydevice as taught herein including devices taught in U.S. Pat. No.8,551,293 in column no. 3, line 30 through column no. 10, and FIGS. 1-9Bthe teachings of which are expressly incorporated by reference hereinregarding angle and height adjustable foil or blades. The foils orblades may be adjusted in angle and/or height as taught herein includingdevices taught in U.S. Pat. No. 9,045,859 in column 1, line 50 throughColumn 16, line 24 and FIGS. 1-9B the teachings of which are expresslyincorporated by reference herein regarding angle and height adjustablefoil blades including cam blocks, grooves, guide keys, connecting rods,thrust end blocks, pivots, foils, pneumatic, hydraulic, bendingstructure or a combination thereof. The wet end includes edges in across-machine direction (i.e., a direction that is perpendicular to amachine direction). The plurality of foils may be broken into one ormore groups of foils and preferably a plurality of groups of foils thatextend in the machine direction. The groups of foils may be all heightadjustable, all angle adjustable, all static, or a combination thereof.The groups of foils may include both height adjustable foils and angleadjustable foils; both static and height adjustable, both static andangle adjustable; height adjustable foils, angle adjustable foils, andstatic adjustable foils; or a combination thereof. The types of bladesmay be alternating (e.g., static blades and height adjustable blades;static and angle adjustable blades; height adjustable blades and angleadjustable blades; or a combination thereof). The static blades may belocated at a beginning and an end and angle adjustable or heightadjustable blades may be located therebetween. The paper machine mayinclude two or more groups of foils, three or more groups of foils, fouror more groups of foils, or five or more groups of foils. Each group offoils may include two or more foils, four or more foils, six or morefoils, or even ten or more foils. A first set of foils may include aforming board and then a set of foils. The types of foils (e.g., static,angle adjustable, height adjustable) may be grouped in any order. Forexample, the group of foils may include two angle adjustable foils thenone static foil and the three height adjustable foils. Each foil may bea different type in an alternating fashion. For example, a static foilthen height adjustable in a repeating pattern. The height adjustablefoils may move a distance from a wire (e.g., out of contact with thewire). The height adjustable foils may move towards or away from thewire. The height adjustable foils may from away from the foil about ±1mm or more, about ±2 mm or more, about ±3 mm or more, about ±4 mm ormore, about ±5 mm or more, or about ±6 mm or more (e.g., when the foilmoves towards the wire it is positive (or up) and when the foil movesaway from the wire it is negative (or down)). When the height adjustableblades are in contact with the wire and the wire is not deflected thenthe height adjustable blades are at 0 mm. The angle adjustable bladesmay be adjustable in an angle from about ±1° or more, about ±2° or more,about ±3° or more, or about ±4° or more (e.g., when a tip of the bladeis rotated into the wire (i.e., up pressing into the wire) the angle ispositive and when the tip of the blade is rotated away from the wire(i.e., down moving away from the wire) the angle is negative, and whenthe tip is parallel to the wire the angle is)0°. The height adjustablefoils may create vacuum on the wire that pulls the wire negative. Theheight adjustable foils may have a “v” shape and the valley of the “v”may assist in pulling the wire below 0° so that stock activity iscreated. The blades may be adjusted based upon one or more monitoredconditions of a monitoring system. Preferably, a monitoring systemmonitors the stock at one or more locations between the headbox and thedry line or a press section.

The monitoring system may function to monitor activity, amplitude, size,scale, duration of activity, or a combination thereof of stock on apaper machine and preferably stock in the wet end of a paper machine.The monitoring system may monitor in the cross-machine direction, themachine direction, or a combination of both. The monitoring system maymonitor activity, amplitude, size, scale, duration of activity, or acombination thereof in a cross-machine direction, a machine direction,or a combination of both. The monitoring system may measure stockactivity, amplitude, size, scale, duration of activity, or a combinationthereof (hereinafter all will be referred to as stock movement). Themonitoring system may monitor stock activity, analyze stock activity,relay information regarding stock activity to a control system, or acombination thereof in real time. The monitoring system may monitor theamount of water removed by one or more of the foils; the forming board;the impingement angle between the stock jet and the wire, the formingboard, or both; each stock section; or a combination thereof. Themonitoring system may monitor the cut through near the head box. Themonitoring system may be located at, alongside, perpendicular to, or acombination thereof a cut through on the paper machine. The cut throughmay be the area between the slice opening and the forming board, betweenthe head box and the forming board, between the breast roll and theforming board, or a combination thereof. The monitoring system maymonitor the width of the water being removed. The monitoring system maymonitor the impingement angle between the stock jet and the formingboard. The monitoring system may monitor the amount of water removed byadjusting a gap between the forming board and the head box, an angle ofone or more blades, a height of one or more blades, or a combinationthereof. The monitoring system may monitor the location of the bottomportion of the head box relative to the breast roll, the forming board,or both. The monitoring system may include one or more lights, one ormore sensors, one or more level devices, or a combination thereof. Themonitoring system may monitor the activity line, the stock activityline, a wet line, dry line, or a combination thereof. Preferably, themonitoring system includes a plurality of sensors that monitor the wetend of the paper machine.

The one or more sensors function to monitor the stock activity (i.e.,movement). The one or more sensors may function to send signals to acontrol system so that the control system controls the stock movement.The one or more sensors function to monitor and assist in controllingstock movement (i.e., activity) in real time so that final paper qualitymay be changed without waiting for testing results from a dry end of apaper machine. The one or more sensors may assist in making adjustmentsduring a grade change, normal running, or both. The one or more sensorsmay monitor a temperature of the stock. The one or more sensors maymonitor a first side and a second side of the stock activity line, thewet line, the dry line, or a combination thereof. The one or moresensors may monitor a temperature profile, a humidity profile, a drynessprofile, or a combination thereof. The one or more sensors may monitorthe stock jet. The one or more sensors may monitor jet impingement ofthe stock jet relative to the slice opening, the wire, the formingboard, the forming board section, or a combination thereof. The one ormore sensors may monitor a location proximate to a steam box. The one ormore sensors may monitor for streaks, temperature profile, drynessprofile, or a combination thereof. The sensors may monitor stockmovement and correlate the stock movement to a previous run and thenprovide signals to the control system to adjust the paper machine tomatch the activity (e.g., stock movement) of the previous run. Thesensors may be a camera that takes still images, moving images, or both.The sensors may use ultrasound, infrared, CMOS sensor, charge-coupleddevice, matrix camera, area scan camera, line scan camera, microwave, atemperature sensor, nuclear, capacitance, pressure, vacuum, distance,suspension height, or a combination thereof. The one or more sensors maybe a plurality of sensors or a multitude of sensors. All of the sensorsmay be the same type of sensor. Different types of sensors may be usedtogether. For example, one sensor may be an infrared sensor and anothersensor may be a CMOS sensor. The one or more sensors may be a colorsensor. The one or more sensors may be monochrome sensor. The one ormore sensors may monitor a dry line without use of cameras (i.e., dryline monitoring may be done without lights). The one or more sensors maybe one or more sensors, two or more sensors, four or more sensors, sixor more sensors, or even ten or more sensors. Each of the sensors mayproduce images that have a plurality of pixels. Each of the sensors mayproduce pixels that may be categorized. The pixels of the sensors may becategorized based upon a primary activity, secondary activity, tertiaryactivity, or more activities (e.g., 4 groups, 5 groups, 6 groups, ormore). The groups of activity may be selected based upon one or morepredetermined activity settings. The groups of activities may becompared to one or more threshold activities. The one or more thresholdactivities may separate the activities into a primary, secondary,tertiary, etc. The primary activity, secondary activity, and tertiaryactivity may be measured by one or more sensors. The one or more sensorsmay include an air purge. The one or more sensors may include a cleaningmechanism. The one or more sensors may include a self-cleaning lens. Theone or more sensors may include a wipeable lens. For example, thewipeable lens may be a self-wiping lens that upon a pre-determinedamount of build-up moves so that the debris is removed from the lens.The lens may move longitudinally or radially so that a cleaned lens ismoved in front of the camera. The one or more sensors may include both acleaning mechanism and an air purge. The one or more sensors may removevapor, fluids, steam, debris, stock, or a combination thereof. The oneor more sensors may be in a location so that the sensors are a highangle sensor, a low angle sensor, a movable sensor, or a combinationthereof.

The one or more movable sensors may be located above the wet end and theone or more movable sensors may move in the machine direction, thecross-machine direction, or a direction therebetween. The movablesensors may function to travel with a location on a wire. The movablesensors may travel with an area of stock. For example, the sensor maymatch the speed of the wire and take readings of the changes occurringto a location on the wire to determine the impact of each foil, section,or both on activity. The movable sensors may move along the stockactivity line, the wet line, the dry line, or a combination thereof. Themovable sensors may be connected on a frame, a wire, may be a drone, maybe free of connection with any devices, may be suspended from a ceiling,may be suspended over the head box and movable along the head box, or acombination thereof. The movable sensors may zoom in, zoom out, or both.The movable sensors may be movable with a light so that an area ofinterest is illuminated while the movable sensor moves. The movablesensors may move diagonally. For example, the movable sensor may move inthe machine direction as the movable sensor scans in the cross-machinedirection so that the movable sensor measures in a straight line acrossthe wire. The movable sensors may be a plurality of sensors. The movablesensors may be a camera, a thermal camera, a temperature sensor, or acombination thereof. There may be multiple movable sensors that moveover the wet end to allow a user to monitor one or more locations of thewet end simultaneously. The movable sensors may be wired, wireless, useBluetooth, use wifi, use radio waves, or a combination thereof. Themovable sensors may be in communication with other sensors and may moveto a location of interest based upon measurements taken by othersensors. The movable sensors and other sensors may be in communicationwith the control system and the control system may control where themovable sensor senses based upon feedback detected by the sensors (e.g.,the high angle sensors, the low angle sensors, or both).

The one or more high angle sensors may function to be located above thewet end and look substantially down at the wet end to monitor the wetend of the paper machine. The high angle sensors may be locatedsubstantially overhead of the wet end. The high angle sensors may beorthogonal to the wire, the wet end, or both. The one or more high anglesensors may monitor a stock activity line, a wet line, a dry line, or acombination thereof. A plurality of high angle sensors may be located inthe cross-machine direction across the paper machine. The high anglesensors may each monitor a portion of a width (i.e., cross-machinedirection) of the paper machine. The high angle sensors may monitoroverlapping regions. The high angle sensors may be located about 90degrees or less, about 75 degrees or less, about degrees or less, orabout 45 degrees or more with the wet end, wire, foil sections, or acombination thereof. The high angle sensors may monitor the stockmovement. Preferably, the high angle sensors monitor activity, size,scale, or amplitude of the stock. The high angle sensors may work inconjunction with or separately from the one or more low angle sensors.

The one or more low angle sensors may function to measure stockmovement. The one or more low angle sensors preferably monitor stockamplitude and/or stock activity. The one or more low angle sensors maybe substantially coplanar with the wire, the foils, the wet end, or acombination thereof. The one or more low angle sensors may be angledparallel to the cross-machine direction, perpendicular to the machinedirection, or both. The one or more low angle sensors may be located asufficient height above a deckle board to monitor stock movement on thewire, the foils, the wet end, or a combination thereof. The one or morelow angle sensors may have an angle of about 0 degrees or more, about 5degrees or more, about degrees or more, about 25 degrees or more, orabout 45 degrees or less with the wire, the foils, the wet end, or acombination thereof. The one or more sensors (e.g., high angle, moving,low angle, or a combination thereof) may monitor the amount of activityof the stock within a given region. For example, the sensors may countthe total number of peaks (i.e., spouts that extend from the wire, whichare shown in the figures as light spots or stock jumping up from thewire) formed in the stock that extend above a predetermined point (e.g.,a level device or activity line). The sensor may monitor the amount ofthe fluid (e.g., water) being removed by each foil. For example, if onefoil is removing too much fluid then the stock activity may be reducedand the fibers froze in place. In another example, if enough fluid isnot removed from a foil or group of foils then a sufficient dryness maynot be achieved. The one or more low angle sensors may monitor each foilor foil section so that substantially the same out of fluid is removedby each foil or foil section. The one or more low angle sensors maymonitor the amplitude of the stock. For example, the low angle sensorsmeasure a height the stock is agitated above the wire, the foils, alevel device, an activity line, or a combination thereof.

The one or more level devices may function to create one or moreactivity lines for comparison. The level devices may create a primaryactivity line, a secondary activity line, a tertiary activity line, or acombination thereof. The one or more level devices may function tocreate an activity line to determine an amplitude, size, scale,duration, activity, or a combination thereof of the stock. The activityline may indicate an area that is being monitored (e.g., a monitoringregion). The one or more level devices may function to assist incategorizing the type of activity and/or amplitude of the stock. Thelevel device may create a physical activity line or activity plane abovethe paper machine that is visible by the sensors so that the sensors candetermine if the activity, amplitude, size, scale, duration, or acombination thereof is above a set point, predetermined amount,calculated amount, or a combination thereof. Preferably, the one or morelevel devices create a computer generated activity line. For example,when an image is captured the monitoring system adds the activity lineinto the image for comparison. The activity line may be an invisibleline that stock may be compared to in order to categorize activity in amonitoring region. The controller may add an activity line, leveldevice, or both into the measured signal so that the stock activity canbe characterized. The activity line and the level device may be aided byone or more lights in monitoring the stock movement.

The one or more lights may function to illuminate the stock movement sothat the stock movement can be measured. The one or more lights may bepart of the monitoring system. The one or more lights may freeze thestock so that the stock activity is visible. For example, the lights maybe a strobe light. The lights may be connected to a monitoring systemthat may control the frequency of the lights turning on and off, thestrobing of the lights, or both. The one or more lights may be connectedto each of the sensors. Preferably, the monitoring system includes aplurality of sensors. Some sensors may be free of lights. The one ormore lights may be a bank of lights. The one or more lights may belocated with each sensor and the lights and sensors may cooperatetogether. The lights may work with any of the sensors. The one or morelights may be a bank of lights. One or more lights or a plurality oflights may be aligned along the wet end of the paper machine. The one ormore lights may assist the monitoring system so that the monitoringsystem may generate and send signals to the control system.

The control system may function to change or adjust one or more papermachine settings. The control system may be connected to a monitoringsystem taught herein. The control system may vary the speed of the wire,angle of the foils, height of the foils, speed of stock coming out ofthe head box, stock jet angle, amount of suction being applied to one ormore sections, vacuum levels, slice opening, stock jet speed, wirespeed, jet to wire ratios, temperature of the stock, head boxconsistency, or a combination thereof. The one control system may be anautomatic control system, a manual control system, or both. The one ormore control systems may adjust an activity line, a stock activity line,or both. The one or more control systems may move a movable sensor. Theone or more control systems may communicate between two or more sensors;a sensor and a light; a level device and a sensor; an activity line anda sensor or a controller; or a combination thereof. The control systemmay include one or more processors, one or more microprocessors, or boththat analyze a plurality of images taken by the sensors and correlatethe sensors to one or more dry end tests so that wet end changes may bemade to effect one or more dry end tests. The control system may monitorin real time. The control system may be a closed loop control system.The control system may adjust the paper machine for changes in furnish,ambient temperature, freeness, or a combination thereof. The controlsystem may calculate positions of the components of the paper machinebased upon measurements form the monitoring system, input measurementsfrom operators, upstream monitoring equipment, or a combination thereof.The control system may adjust for ambient lighting conditions. Forexample, if it is night then the control system may measure the activitydifferently than if it is day outside. The lights may flood themonitoring region so that the time of day and ambient light do notaffect the measurements. The control system may be part of a distributedcontrol system (DCS). The control system may be part of the monitoringsystem. The control system may be in communication with one or morecontrollers.

The one or more controllers may be in communication with one or morecomponents such as the head box, foils, groups of foils, wire, suctionboxes, couch roll, breast roll, dilution controllers, angle adjustablefoils, height adjustable foils, steam boxes, temperature controldevices, or a combination thereof. The one or more controllers may bemanually controlled, automatically controlled, or both. Each component(e.g., sensor, foil, foil motor, head box motor, slice opening, steambox, activity shower) may include a controller so that each componentmay be controlled independently or individually without reference toother components. The controllers may be remotely controlled (e.g., by aDCS, remote, or tablet). The controllers may be controlled by a wire.The controllers may be wirelessly controlled. The controllers may belocally controlled (e.g., a user standing by the paper machine manuallyactuating the controller or pressing a button). The controller may becontrolled based upon stock activity, amplitude, size, scale, durationof activity, or a combination thereof. The controller may be aproportional controller, integral controller derivative controller,Proportional Integral Derivative controller, or a combination thereof.

The stock activity may be the number of spouts in a given region (e.g.,a monitoring region). The activity may be a measured amount of spoutsthat extend above an activity line (e.g., amplitude). The activity maybe counted. The activity may be based on an average amplitude of thespouts, a quantity of spouts in a monitored region, scale of the spouts,duration of the spouts, or a combination thereof. The activity line maybe a predetermined line that may be determined based upon correlationwith dry end measurements. The activity line may be a primary activityline and a secondary activity line. Activity that extends above theprimary activity line may be primary activity and activity that extendsabove the secondary activity line may be secondary activity. Thus, theactivity may be categorized based on activity relative to the activityline. The activity may be any region in the stock that is notsubstantially flat or created by waves. The activity may be individualstock interruptions that spout above the surrounding stock. The activitymeasurement may be the number of spouts within a given monitoringregion. The activity measurement may be a measurement of the number ofspouts in a monitoring region above an activity line.

The amplitude of stock may be a spout of stock with a height above anactivity line, above a predetermined point, or both. The amplitude mayany spout that extends above the surrounding stock. The spouts may begraphically represented by peaks that extend upward and taper to a peak.The stock amplitude may be categorized relative to a height of the wire,the surrounding stock, one or more activity lines, or a combinationthereof. The amplitude may be the height of the spouts. The amplitudemay represent an amount of activity input into the stock by the foils,the stock jet, or both. The amplitude may be divided into primaryactivity, secondary activity, tertiary activity, or a combinationthereof. The stock activity may be monitored for amplitude, size,duration, or a combination thereof.

The size of the spouts may be a cross-sectional thickness of the spoutat a predetermined location. The size of the spouts may be measured atthe activity line, before the activity line, between the activity lineand the head box; or a combination thereof. The size of the spouts mayvary over the height of the spouts. The size of the spouts may vary asthe spouts are measured in the machine direction. The spouts maydecrease in size as the spouts are measured in the machine direction.For example, the spouts in the first section may be larger than thespouts in the second section. The activity line (e.g., primary activityline, secondary activity line, tertiary activity line) may vary alongthe machine direction. For example, as the consistency increases, due todewatering, the size, amplitude, total activity, or a combinationthereof may decrease such that the activity line may be calibrated ateach section to accommodate for the increase in the consistency (e.g.,more fibers by weight). The size of the spouts and the amplitude of thespouts may be directly proportional. The size of the spouts and theamplitude of the spouts may be conversely proportional.

The duration of activity may be the distance the spouts are formed aftera foil or the duration spouts are created after a foil is adjusted. Theduration of activity may be measured in the machine direction. Theactivity line may be a line that separates upstream of the activity linefrom downstream of the activity line so that activity before the lineand the activity after the line can be measured determine the amount ofactivity that lasts a duration beyond the activity line. The duration ofactivity may be measured in seconds after a foil change. The duration,amplitude, stock activity, size, scale, or a combination thereof may bemeasured in a monitoring region.

The scale may be the distance between spouts, a cross-sectionalthickness (e.g., diameter) of the spouts, or both. The scale may bemeasured in sections across the paper machine. The scale may correlateto the density of the activity. The scale or density may be directlyproportional. The scale may be a number of spouts within a given area(e.g., density). The activity line may create a perimeter around aregion of stock so that the activity within the region may be measured.The scale may be measured in a primary activity, a secondary activity, atertiary activity, or a combination thereof depending upon thecategorization of the activity.

The primary activity may function to indicate an amount of activity thatexceeds a threshold amount of activity. The primary activity may be anyactivity that is over a threshold activity (e.g., over a primaryactivity line). The threshold activity may be amplitude, size, scale,duration, amount, height, or a combination thereof. Primary activity mayindicate that the stock will achieve the desired dry end testingcharacteristics. The primary activity at each section may be about 20percent or more, about 30 percent or more, about 40 percent or more,about 50 percent or more. The primary activity at each section may beabout 90 percent or less, about 80 percent or less, or about 70 percentor less. The primary activity may be measured by establishing a primaryactivity line and a secondary activity line. Any activity over theprimary activity line may be considered primary activity, any activitybetween the primary activity line and the secondary activity line may besecondary activity, and any activity below the secondary activity linemay be tertiary activity line. More or less activity lines may beestablished depending upon desired levels of activity. The activitylines may be based upon amplitude of the stock. For example, a height ofthe droplets of stock over the wire may be measured and the number ofpeaks over the primary activity line may establish the primary activity.The number of peaks that fall between the primary activity line and thesecondary activity line may establish the secondary activity, and theremaining peaks may establish the tertiary activity. A total activitymay be calculated by adding the primary activity, secondary activity,and tertiary activity together so that a percentage of each may becalculated. The primary activity may decrease from a first section to asecond section, a second section to a third section, or a third sectionto a fourth section. The activity lines may be adjusted to account forless activity as the paper sheet becomes drier. An amount of primaryactivity may be the lowest as the wire travels from the head box towardsthe press section. The primary activity at the stock activity line maydrop to about 10 percent or less, about 5 percent or less, or about 0percent. The primary activity may decrease from foil section to foilsection. The primary activity in a first section (i.e., the sectionclosest to the head box) may be between about 60 percent and 30 percent,between about 55 percent and about 35 percent activity, preferablybetween about 50 percent and about percent of the total activity (i.e.,about 42 percent of the total activity). The primary activity my lowerfrom section to section. The primary activity may decrease by about 5percent or more, about 10 percent or more, or about 15 percent or morefrom section to section. The primary activity may decrease by about 30percent or less, about 25 percent or less, or about 20 percent or less.The primary activity may have a greatest decrease from the first foilsection to the second foil section. For example, from a first foilsection to a second foils section the primary activity may decrease byabout 20 percent of the total activity, and from the second foil sectionto the second foil section the primary activity may decrease by about 15percent of the total activity. The amount of primary activity may bevaried from grade to grade. The primary activity may be varied bychanging a primary activity line. The primary activity line may bedetermined by a percentage of a peak height. For example, if a peakheight is 3 mm then the primary activity line may be set at 75 percentof a peak height (i.e., 2.25 mm). The peak height may be about 50percent or more, about 60 percent or more, about 70 percent or more,about percent or more, or about 80 percent or more of a peak height(e.g., amplitude) of the activity. The primary activity may change tosecondary activity as measurements are taken in the machine direction.For example, in the first section the primary activity may be about 41percent and the secondary activity may be about 3 percent and then inthe second section the primary activity may be about 22 percent and thesecondary activity may be about 4 percent.

The secondary activity may be activity that greater than tertiaryactivity but not as great as primary activity. The secondary activitymay indicate activity in a foil section, but the activity may be below athreshold amount or measurement. The secondary activity may indicatethat activity is being imparted into a foil section, but that an amountof activity is not sufficient to generate primary activity or that aconsistency has reached a level such that primary activity is limited.The secondary activity may be changed to primary activity by adjustingone or more settings. The secondary activity may be changed to primaryactivity by changing height of one or more height adjustable foils,changing angle of one or more angle adjustable foils, changing height ofa plurality of height adjustable foils, changing angle of a plurality ofangle adjustable foils, changing steam boxes, adjusting vacuum,adjusting formation showers, or a combination thereof. The secondaryactivity may be increased or decreased by increasing or decreasing anamount of vacuum applied to the foil sections. The secondary activitymay be varied by adjusting a slice opening, stock jet, speed of thewire, or a combination thereof. The secondary activity may be ameasurement of an amplitude of the stock. For example, if 1000 peaks aremeasured in a monitored region then a number is counted that fallbetween a primary activity line and a secondary activity line. Thesecondary activity may be a concentration of activity within a region. Adensity of peaks may be considered activity. For example, if there are20 peaks or more in a 1 m×1 m area then that density of peaks may beconsidered secondary activity. The secondary activity may stayconsistent from foil section to foil section. For example, as theconsistent increases the secondary activity may decrease and thesecondary activity may remain consistent. The secondary activity at thestock activity line may drop to about 5 percent or less, about 2 percentor less, or about 0 percent. The secondary activity may decrease fromfoil section to foil section. The secondary activity in a first section(i.e., the section closest to the head box) may be between about 40percent and 1 percent, between about 30 percent and about 2 percentactivity, preferably between about 15 percent and about 2.5 percent ofthe total activity (i.e., about 3 percent of the total activity). Thesecondary activity my lower from section to section. The secondaryactivity may remain consistent from section to section. The secondaryactivity may decrease by about 5 percent or less, about 2 percent orless, or about 0.5 percent or less from section to section. Thesecondary activity may decrease by about 30 percent or less, about 25percent or less, or about 20 percent or less from section to section.The amount of secondary activity may be varied from grade to grade. Thesecondary activity may be varied by changing a primary activity line, asecondary activity line, or both. The secondary activity line may bedetermined by a percentage of a peak height. For example, if a peakheight is 3 mm then the secondary activity line may be set at 60 percentof a peak height (i.e., 1.8 mm). The peak height may be about 30 percentor more, about 40 percent or more, about 50 percent or more, about 55percent or more, or about percent or more of a peak height (e.g.,amplitude) of the activity. The secondary activity may change totertiary activity as measurements are taken in the machine direction.For example, in the first section the secondary activity may be about 4percent and the tertiary activity may be about 50 percent and then inthe second section the secondary activity may be about 3 percent and thetertiary activity may be about 70 percent.

The tertiary activity may be any activity that falls below a thresholdmeasurement. The tertiary activity may be laminar flow, low turbulenceflow, stock that does not include peaks (i.e., amplitude), or acombination thereof. The tertiary activity may be any activity thatfalls below a threshold (e.g., a determination for secondary activity).The tertiary activity may increase as the stock travels towards theactivity line. At the activity line all of the stock may be tertiaryactivity. Once the consistency reaches 3 percent or more, four percentor more, or even percent or more all of the activity may become tertiaryactivity.

The monitoring region may be a predetermined region, a standard region,or both. The monitoring region may be a section in the cross-machinedirection. The monitoring region may have a dimension in thecross-machine direction and a dimension in the machine direction so thatan area is formed. A plurality of monitoring regions may exist in thecross-machine direction. A plurality of monitoring regions may belocated side by side and span across the cross-machine direction. Themonitoring regions may be aligned with an activity line so that spoutsabove a predetermined activity line can be measured in each monitoringregion. The monitoring regions may span between the head box and theactivity line. The monitoring regions may have a length that is equal tothe length of a foil section. The monitoring regions may have a widththat is equal to ⅛ or more, ¼ or more, ½ or more of a cross section of apaper machine. The monitoring regions may have a width that is equal toa width of the paper machine or less or about ¾ or less of across-section of a paper machine. The monitoring region may cover anystandard area. An area of about 0.25 m² or more, about 0.5 m² or more,about 1 m² or more, about 2 m² or more, about 10 m² or less, or about 5m² or less may be monitored. The monitoring regions may be in the middleof the paper machine, on an edge of the paper machine, may be from oneedge to a second opposing edge, or a combination thereof. The monitoringregion may monitor a height above the monitoring region (and the area).The height monitored may be about 1 cm or more, about 2 cm or more,about 5 cm or more, about 10 cm or more, about 100 cm or less, about 75cm or less, or about 50 cm or less above an activity line. The heightmonitored may extend above and below an activity line. The heightmonitored above the activity line may be equal to a height monitoredbelow an activity line.

The activity line may be a standard line that activity, spout heights(i.e., amplitude), or both are compared. The activity line may belocated a predetermined distance above the wire, foils, or both. Theactivity line may be the height of stock in the absence of activity. Theactivity line may be the same height for all grades. The activity linemay be changed for each grade. The activity line may be about 1 cm ormore, about 2 cm or more, about 5 cm or more, about 10 cm or more, about50 cm or less, about 25 cm or less above the wire, the foils, or both.The activity line may be a plurality of activity lines. Each line mayseparate the activity into a different category. The activity lines maybe a primary activity line, secondary activity line, tertiary activityline, or a combination thereof. The activity lines may measure aquantity of activity that extends above the activity line, between twoactivity lines, below an activity line, or a combination thereof. Theactivity lines may be an arbitrary line that may be moved depending onsheet formation characteristics, dry end testing requirements, wirespeed,

The monitoring system may monitor and/or control with a method. Themethod may include one or more steps performed in any order. The methodmay monitor the stock movement or stock activity. The stock activity maybe compared to a reference stock activity or an activity line. The stockactivity may be compared to a saved stock activity from a prior run of apaper grade. The stock activity may be compared to a saved stockactivity when a wire is a similar worn condition. For example, if thewire is 30 days old then the stock activity is compared to a referenceactivity on the paper machine when the wire is 30 days old. A changebetween the monitored activity and the reference activity are compared.The change is compared to a predicted formula, a predicted change, orboth. The method may include a step of categorizing the stock activity.The stock activity may be categorized into primary activity, secondaryactivity, tertiary activity, or a combination thereof. The change isused to predict the position of the components on the paper machine tolower the change. The change is compared to one or more stock movementsand the stock movements after the change are predicted. If the change isreduced to zero the monitoring system may predict the impact on finalproperties of the paper, the formation of the paper, or both. Themonitoring system may predict paper properties based upon the positionsof the components on the paper machine, or the movement of thecomponents on the paper machine (e.g., foils, head box, suction, speed,or any others discussed herein). The method may include a step ofpredicting paper properties. The method may include a step of comparingthe predicted paper properties to a target sheet formation, andcalculating a formation error. The method may include a step ofcomparing predicted paper properties to paper properties measured at thedry end. The monitoring system may predict paper properties based uponactivity, a ratio of primary activity to secondary activity and/ortertiary activity, or both. The monitoring system may indicate whereadjustment is needed so that a user may make an adjustment. The user maymake adjustments from a distal location from the paper machine, fromproximate to the paper machine, or both. The monitoring system, controlsystem, or both may atomically make adjustments. The method includes astep of a user inputting a desired adjustment to one or more papermachine components (e.g., foils, head box, etc.) from a remote location,a proximate location, or both. The monitoring system may begin review atthe head box and move towards the dry end as the activity changes andimpacts are monitored. A new target formation or properties arecalculated based upon the calculated changes. A new predicted formationis calculated based upon the change in the paper machine components. Ifa target formation is not achieved then the steps may be repeated one ormore times until target formation is achieved. The difference betweenthe predicted and the actual stock movement, paper machine properties,or both are calculated. The difference between the predicted and theactual may be used to correlate to a formation error. The differencebetween the predicted and the actual may be used to move one or morecomponents of the paper machine. The difference between the predictedand the actual may be used to calculate a distance of movement of thefoils, the position of the foils, the speed of the wire, the speed ofthe stock, the slice opening size, the amount of vacuum, or acombination thereof. The process may be repeated for each section of thepaper machine. The process may begin at the head box, the slice opening,the first foil section, or a combination thereof. The process maymonitor a paper machine with the monitoring system taught herein, andcontrol the paper machine with the control system taught herein. Thecontrol system, controller, monitoring system, or a combination thereofmay include memory. The control system, controller, monitoring system,or a combination thereof may record positions of each component of thepaper machine (e.g., foil positions, machine speed, slice opening, stockjet velocity). The method includes a step of changing one or more of thecomponents to a pre-recorded position in anticipation of a grade change,during a grade change, or at a beginning of a grade change.

FIG. 1A illustrates a perspective view of a paper machine 2 thatincludes a monitoring system 20 and a control system 40. The papermachine 2 includes a head box 4 that puts stock (not shown) on a wire 6as the wire 6 continuously moves. The wire 6 travels under the headbox 4to receive the stock and then over a plurality of foil sections 8 thatremove water from the stock which creates a dry line 12 in the stock.The wire 6 ends at the couch roll 10 where the wire 6 turns and extendsin a reverse direction. A monitoring system 20, monitors one or morelocations between the headbox 4 and the couch roll 10. The monitoringsystem 20 as shown includes a plurality of lights 22, plurality ofsensors 24, and one or more level devices to monitor process conditionsof the stock (not shown) along or across the wire 6. The monitoringsystem 20 includes high angle sensors 26 and low angle sensors 28. Thelow angle sensors 26 are located substantially level with the wire 6 andinclude a level device 30 that projects an activity line 74 that extendssubstantially parallel to the wire 6. The activity line 74 assists themonitoring device is measuring an amount of amplitude of the stock onthe wire 6. Preferably, the activity line 74 assists in measuring theamplitude of the stock in a foil section 8. As shown, the low anglesensor 28 extends at an angle (β) or distance relative to the wire 6 orstock (not shown). The activity line 74 as shown extends at an angle(Φ⁻) or distance above relative to the wire 6 or stock (not shown)although the activity line 74 may extend parallel to the wire or stockin a cross direction. The activity line 74 as shown extends at an angle(Φ⁺) or distance below relative to a sight line of the low angle sensor28. The high angle sensors 26 have a sight line that extends at an angle(α) relative to the wire or stock. The control system including acontroller 42 is connected to the monitoring system 20 and the papermachine 2 and preferably the foil sections 8 to control movement of theindividual foils (not shown) within the foil sections 8.

FIG. 1B is a top view of a low angle sensor 28, which is positioned toview parallel to the wire 6 in the cross-machine direction as stock (notshown) travels in the machine direction 14. The low angle sensor 28includes a level device 30 that produces an activity line 74. The lowangle sensor 28 measures the activity created by a foil section 8relative to the activity line 74. The sensor 24, which as shown, is alow angle sensor 28 is in communication with a control system (notshown).

FIG. 10 is a side view of FIG. 1B along line 10-10 so that the sideprofile of the stock 60 is shown. The profile looking in thecross-machine direction is shown as the stock 60 travels on the wire 6in the machine direction 14. The sensor (not shown) measures theamplitude 68 created by the foils 9 above an activity line 74.

FIG. 1D is a side view of a paper machine 2 with a monitoring system 20.The paper machine 2 includes a head box 4 with a slice opening 3. Stock(not shown) exits the head box 4 from the slice opening 3 and unto awire 6 located above a forming board 7 in a forming section 130. Thestock travels with the wire 6 from the forming section 130 to s132,second section 134, and the third section 136. The monitoring system 20has a plurality of sensors 24 that monitor stock activity (not shown) asthe stock travels along the paper machine 2. The monitoring system 20includes a plurality of sensors 24, with one sensor 24 monitoring theforming section 130, two sensors 24 monitoring the first section 132,three sensors 24 monitoring the second section 134, and two sensors 24monitoring the third section 136. The monitoring system 20 includes amovable sensor 25 that is movable in the cross-machine direction, themachine direction, or both. The monitoring system 20 also includes asensor 24 that monitors the dry line (not shown). The monitoring system20 further includes lights 22 that illuminate the sections of the papermachine during use of the monitoring system 20. The monitoring system 20is connected to a control system 40 that includes one or morecontrollers 42 that adjust one or more elements in the forming section130, first section 132, second section 134, and/or third section 136 tochange stock activity in the respective section.

FIG. 2A is a perspective view of activity 66 (visible as white dots) ofstock 60 from a low angle sensor (not shown). The stock activity 66 asshown has an amplitude 68.

FIG. 2B illustrates activity 66 (visible as white dots and stock/fluidextending up) of stock 60 after a foil (not shown) has been adjustedfrom that of FIG. 2A. The amount of activity 66 is increased (by afactor of 3 or more or preferably 4 or more) and the amplitude 68 isincreased (by a factor of 2 or more, 3 or more, or even 4 or more).

FIG. 3A illustrates a side view of stock 60 so that the amplitude 68 andactivity 66 of the stock 60 is visible.

FIG. 3B illustrates a side view of stock 60 after a foil change so thatamplitude 68 increases and activity 66 is increased.

FIG. 4 is an analysis of FIG. 3B where the activity 66 and amplitude 68of the stock 60 in the machine direction 14 above an activity line 74generated by a level device (not shown), which is computer generated foranalysis purposes, are highlighted for analysis.

FIG. 5 is a pictorial demonstration of the analysis of stock 60 as thewater 64 is removed from the stock 60 by a foil 9. The stock 60 andfiber 62 move along the wire 6 and the foil 9 creates stock activity 66(e.g., pulse density and duration) and amplitude 68 (e.g., height). Themonitoring system (now shown) measures the stock activity 66 andamplitude 68 above an activity line 74.

FIG. 6 illustrates the stock 60 and high angle sensor 26 with a light 22that monitor at an angle (a) relative to the stock 60.

FIG. 7A illustrates a top view of stock 60 from a high angle sensor (notshown). The activity 66 (e.g., white spots) of the stock 60 is visible.

FIG. 7B illustrates a top view of stock 60 from a high angle sensor (notshown) after a foil change. The stock activity 66 is substantiallyincreased (e.g., 2 or more times, 3 or more times, 4 or more times, oreven 5 or more times) after the foil change.

FIG. 8A illustrates a top view of stock 60 from a high angle sensor (notshown) before a foil change where stock activity 66 are visible.

FIG. 8B shows a change in activity 66 in the stock 60 when a foil isadjusted. Monitoring regions 70 are added to the images to correlatethat amount of activity 66 relative to each foil (not shown).

FIG. 9 shows an activity measurement 72 showing the amount of activity66 of the stock 60 above the activity line (not shown) or relative to abase line measurement in each monitoring region 70.

FIG. 10A is a process diagram 100 where the current camera activity 102is monitored. The monitored current camera activity 102 is compared to areference activity 104 and an activity change 106 is calculated. Theactivity change 106 is monitored relative to formation to determine theimpact of activity on formation and then a formation level is predicted110. The predicted formation 110 (i.e., current formation level) iscompared to a target sheet formation 112 to determine a change information desired or formation error 114. The formation error 114 iscompared to a blade position 116 and then the blade position is changed118 to adjust the activity and formation of the stock.

FIG. 10B is a process diagram 100 where the current camera activity 102is monitored. The monitored current camera activity 102 is compared to areference activity 104 and an activity change 106 is calculated. Theactivity change 106 is monitored relative to formation to determine theimpact of activity on formation and then a formation level is predicted110. The predicted formation 110 (i.e., current formation level) iscompared to a target sheet formation 112 to determine a change information desired or formation error 114. The formation error 114 iscompared to the current paper machine settings and adjustment of papermachine parameters 120 (e.g., consistency, blade angle, slice opening,blade angle, blade height, forming board position). The paper machineparameters are changes 122 according to formation error 114. The papermachine activity is reviewed 124 for the current activity after thechange. The current activity after the change is compared to apredetermined parameter of baseline activity 126. If the parameter isnot met at step 126 then go back to step 102 and repeat. If theparameter is met at step 128 then proceed to the next section 128 andthen begin at step 102 for the next section downstream.

FIG. 11 illustrates a wet end 18 of a paper machine 2 including a headbox 4 that moves stock through a slice opening 3 forming a stock jet 16.The stock jet 16 extends towards the breast roll 5 and the wire 6 at anangle such that some water 11 is removed by passing through the wire 6proximate to the forming board 7. The wire 6 then moves the stock acrossblades, which as shown are an angle adjustable foil 9A and then a heightadjustable foil 9B that both remove water 11. The angle adjustable foils9A and the height adjustable foils 9B each affect activity of the stockon the wire 6 based upon their respective position.

FIG. 12 illustrates the relationship of wet end 18 pieces relative toeach other. The head box 4 has a slice opening 3 with a gap (A) settinga height and a distance (B) a bottom portion of the head box 4 extendstowards the forming board 7. The bottom portion of the head box 3 islocated a distance (C) from the forming board 7, which has a length (D).An end of the forming board is located a distance (H) from a foil 9,which has a length (E). The angle of the stock jet 16 out of the sliceopening 3 determines the length (F), which is the distance from thebottom of the head box to the point where the stock impinges with thewire 6. Distance (G) is the distance from the forming board 7 to thepoint where the stock impinges the wire 6.

FIG. 13 illustrates a dry line 12, wet line 76, and activity line 74within the wet end 18.

FIG. 14A is an example of a foil configuration setting where a majorityof the stock activity 66 is tertiary activity 67C. Activity, as shown,is not imparted into the stock 60 as the stock 60 moves with the wire 6in the machine direction 14. The angle adjustable foils 9A are incontact with the wire 6 and removing water 11 and the height adjustablefoils 9B are out of contact with the wire 6.

FIG. 14B is an example of a foil configuration setting where the stockactivity 66 has a combination of primary activity 67A and secondaryactivity 67B. Activity is imparted into the stock 60 by both the angleadjustable foils 9A and the height adjustable foils 9B as the stock 60moves with the wire 6 in the machine direction 14. Both the angleadjustable foils 9A and the height adjustable foils 9B are in contactwith the wire 6 and are removing water 11. As shown, stock activity 66is increased on a leading side of the height adjustable foils 9B so thatturbulence is generated to increase both stock activity 66 and amplitude68.

FIG. 14C is an example of a foil configuration setting where the stockactivity 66 has a combination of primary activity 67A and secondaryactivity 67B. Activity is imparted into the stock 60 by both the angleadjustable foils 9A and the height adjustable foils 9B deflecting thewire 6 as the stock 60 moves with the wire 6 in the machine direction14. As shown, turbulence as stock activity 66 is formed at a leadingedge of the height adjustable blades 9B and the trailing side of theangle adjustable blades 9A. Both the angle adjustable foils 9A and theheight adjustable foils 9B are in contact with the wire 6 and areremoving water 11. As shown, as the wire 6 moves in the machinedirection 14 the stock activity 66 increases.

FIG. 14D is a side view of a foil section 8, which is a first section132. The foil section 8 as shown includes angle adjustable foils 9A,height adjustable foils 9B, and static foils 9C.

FIG. 15A is an example of a foil configuration setting where a majorityof the stock activity 66 is tertiary activity 67C. Activity, as shown,is not imparted into the stock 60 as the stock 60 moves with the wire 6in the machine direction 14. The height adjustable foils 9B are incontact with the wire 6 at a same plane as the static foils 9C so thatwater 11 is removed but a low amount of activity is imparted on the wire6.

FIG. 15B is an example of a foil configuration setting where the stockactivity 66 and amplitude 68 are increased relative to the foilconfiguration of FIG. 15A, the foil configuration setting has acombination of primary activity 67A and secondary activity 67B. Activityis imparted into the stock 60 by the height adjustable foils 9Bdeflecting the wire 6 between the static foils 9C as the stock 60 moveswith the wire 6 in the machine direction 14. Both the static foils 9Cand the height adjustable foils 9B are in contact with the wire 6 andare removing water 11. As shown, as the wire 6 moves in the machinedirection 14 the stock activity 66 increases. As shown, as the wire 6moves in the machine direction 14 the stock activity 66 increases on atrailing side of the height adjustable foils 9B.

FIG. 15C is a side view of a foil section 8 that is a second section134. The foil section 8 includes alternating static foils 9C and heightadjustable foils 9B.

FIG. 16A is an example of a foil configuration setting where a majorityof the stock activity 66 is tertiary activity 67C. Activity, as shown,is not imparted into the stock 60 as the stock 60 moves with the wire 6in the machine direction 14. The angle adjustable foils 9A are incontact with the wire 6 at a same plane as the static foils 9C so thatwater 11 is removed but a low amount of activity is imparted on the wire6.

FIG. 16B is an example of a foil configuration setting where the stockactivity 66 has a combination of primary activity 67A and secondaryactivity 67B. Activity is imparted into the stock 60 by the angleadjustable foils 9A deflecting the wire 6 between the static foils 9C asthe stock 60 moves with the wire 6 in the machine direction 14. Both theangle adjustable foils 9A and the static foils 9C are in contact withthe wire 6 and are removing water 11. As shown, as the wire 6 moves inthe machine direction 14 the stock activity 66 and amplitude 68increase. Stock activity 66 is created on a trailing side of the angleadjustable foils 9A that assists in increasing amplitude 68.

FIG. 16C is a side view of a foil section 8 that is a third section 136.The foil section 8 includes static foils 9C at the ends and angleadjustable foils 9A between the static foils 9C.

FIG. 17A is a screen shot illustrating the categorization of stockactivity 66 within a monitoring region 70. The monitoring regionincludes mainly primary activity 67A, some secondary activity 67B, andsome intermittent tertiary activity 67C.

FIG. 17B is a screen shot illustrating the categorization of stockactivity 66 within a monitoring region 70. The monitoring regionincludes mainly primary activity 67A, some secondary activity 67B, andsome intermittent tertiary activity 67C. The amount of primary activity67A is decreases relative to the screen shot of FIG. 17A and thetertiary activity 67C is increased in FIG. 17B relative to FIG. 17A.

FIG. 17C is a screen shot illustrating the categorization of stockactivity 66 within a monitoring region 70. The monitoring regionincludes mainly primary activity 67A, some secondary activity 67B, andsome intermittent tertiary activity 67C. The tertiary activity 67C isgreater in FIG. 17C than in FIG. 17A and 17B, and the primary activity67A is the lowest in FIG. 17C relative to FIG. 17A and 17B.

FIG. 17D is a screen shot illustrating the categorization of stockactivity 66 within a monitoring region 70. The monitoring regionincludes mainly primary activity 67A, some secondary activity 67B, andsome intermittent tertiary activity 67C. The tertiary activity 67C isgreater in FIG. 17D than in FIG. 17A, 17B, and 17C, and the primaryactivity 67A is the lowest in FIG. 17D relative to FIG. 17A, 17B, and17C. FIG. 17A-17D are a progression of screen shots in the machinedirection and demonstrate that as water is removed from the stock theactivity level of the stock decreases.

Any numerical values recited herein include all values from the lowervalue to the upper value in increments of one unit provided that thereis a separation of at least 2 units between any lower value and anyhigher value. As an example, if it is stated that the amount of acomponent or a value of a process variable such as, for example,temperature, pressure, time and the like is, for example, from 1 to 90,preferably from 20 to 80, more preferably from 30 to it is intended thatvalues such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expresslyenumerated in this specification. For values which are less than one,one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate.These are only examples of what is specifically intended and allpossible combinations of numerical values between the lowest value andthe highest value enumerated are to be considered to be expressly statedin this application in a similar manner.

Unless otherwise stated, all ranges include both endpoints and allnumbers between the endpoints. The use of “about” or “approximately” inconnection with a range applies to both ends of the range. Thus, “about20 to 30” is intended to cover “about 20 to about 30”, inclusive of atleast the specified endpoints.

The disclosures of all articles and references, including patentapplications and publications, are incorporated by reference for allpurposes. The term “consisting essentially of” to describe a combinationshall include the elements, ingredients, components or steps identified,and such other elements ingredients, components or steps that do notmaterially affect the basic and novel characteristics of thecombination. The use of the terms “comprising” or “including” todescribe combinations of elements, ingredients, components or stepsherein also contemplates embodiments that consist essentially of or evenconsists of the elements, ingredients, components or steps.

Plural elements, ingredients, components or steps can be provided by asingle integrated element, ingredient, component or step. Alternatively,a single integrated element, ingredient, component or step might bedivided into separate plural elements, ingredients, components or steps.The disclosure of “a” or “one” to describe an element, ingredient,component or step is not intended to foreclose additional elements,ingredients, components or steps.

It is understood that the above description is intended to beillustrative and not restrictive. Many embodiments as well as manyapplications besides the examples provided will be apparent to those ofskill in the art upon reading the above description. The scope of theinvention should, therefore, be determined not with reference to theabove description, but should instead be determined with reference tothe appended claims, along with the full scope of equivalents to whichsuch claims are entitled. The disclosures of all articles andreferences, including patent applications and publications, areincorporated by reference for all purposes. The omission in thefollowing claims of any aspect of subject matter that is disclosedherein is not a disclaimer of such subject matter, nor should it beregarded that the inventors did not consider such subject matter to bepart of the disclosed inventive subject matter.

-   -   2 Paper machine    -   3 Slice opening    -   4 Headbox    -   5 Breast roll    -   6 Wire    -   7 Forming Board    -   8 Foil sections    -   9 Foil    -   9A Angle adjustable foil    -   9B Height adjustable foil    -   9C Static Foils    -   10 Couch roll    -   11 Removed water    -   12 Dry Line    -   14 Machine Direction    -   16 Stock jet    -   18 Wet end    -   20 Monitoring system    -   22 Light    -   24 sensor    -   25 Movable sensor    -   26 High angle sensors    -   28 Low angle sensor    -   30 Level device    -   40 Control System    -   42 controller    -   60 Stock    -   62 Fiber    -   64 water    -   66 Stock Activity    -   67A Primary Activity    -   67B Secondary Activity    -   67C Tertiary Activity    -   68 Amplitude    -   70 Monitoring Region    -   72 Activity measurement    -   74 activity line    -   76 Wet line    -   78 Stock activity line    -   100 Process    -   102 Monitored activity    -   104 Reference activity    -   106 Change between 102 and 104    -   108 Correlate the amplitude change to impact on formation    -   110 Predict what formation will look like    -   112 Compare predicated formation to target formation    -   114 Difference between 110 and 112    -   116 Correlate how much blade change is required to remove        formation error 114    -   118 Change blade position    -   120 Adjust paper machine parameter    -   122 Change Slice Opening, Consistency, Blade Angle, Blade Height    -   124 Review and move    -   126 Activity in Parameter    -   128 Move to next section and repeat steps    -   130 Forming section    -   132 First section    -   134 Second section    -   136 Third section

1-17. (canceled)
 18. A method comprising: a. monitoring one or moreregions of a paper machine to obtain current activity of the one or moreregions; b. comparing the current activity to a reference activityrespectively to determine a difference in activity of the one or moreregions; and c. characterizing the difference in the activity as aprimary activity, a secondary activity, or a tertiary activity. 19-20.(canceled)
 21. The method of claim 18, comprising forming a primaryactivity line, a secondary activity line, a tertiary activity line, or acombination thereof.
 22. The method of claim 21, wherein one or morelevel devices create the primary activity line, the secondary activityline, a tertiary activity line, or a combination thereof.
 23. The methodof claim 18, wherein the one or more regions of a paper machine are afirst section, a second section, and a third section.
 24. The method ofclaim 23, wherein an amount of the primary activity of the first sectionis compared to the second section and/or the third section and an amountof the primary activity of the second section is compared to the thirdsection.
 25. The method of claim 18, comprising predicting paperproperties based upon a ratio of the primary activity to the secondaryactivity and/or the tertiary activity.
 26. The method of claim 18,comprising monitoring one or more of the one or more regions with a highangle sensor.
 27. The method of claim 18, comprising determining achange in formation desired or a formation error.
 28. The method ofclaim 27, comprising comparing the formation error to current papermachine settings.
 29. The method of claim 18, wherein the currentactivity includes turbulence of a wet end of the paper machine.
 30. Themethod of claim 18, wherein the monitoring is performed with a pluralityof cameras located at a wet end of the paper machine.
 31. The method ofclaim 30, further comprising: analyzing the current activity in realtime and graphically represented the current activity by peaks.
 32. Amonitoring system comprising: a plurality of sensors located at one ormore regions of a paper machine that monitor current activity of the oneor more regions of the paper machine; and a controller configured to:compare the current activity to a reference activity to determine adifference in activity of the one or more regions; and characterize thedifference in activity of the one or more regions as a primary activity,a secondary activity, or a tertiary activity; wherein the plurality ofsensors include cameras that take still images, moving images, or both.33. The monitoring system or claim 32, wherein the current activityincludes turbulence of a wet end of the paper machine.
 34. Themonitoring system of claim 32, further comprising: one or more leveldevices that form a primary activity line, a secondary activity line, atertiary activity line, or a combination thereof that forms thereference activity.
 35. The monitoring system of claim 32, wherein thecontroller predicts paper properties based upon a ratio of the primaryactivity to the secondary activity and/or the tertiary activity.
 36. Themonitoring system of claim 35, wherein the controller determines achange in formation or a formation error based on the predicted paperproperties.
 37. The monitoring system of claim 36, wherein thecontroller compares the formation error to current settings of the papermachine.
 38. The monitoring system of claim 32, wherein the cameras arehigh angle cameras that are angled downward towards the paper machine.39. The monitoring system of claim 32, wherein the controller analyzesthe current activity in real time and graphically represents the currentactivity by peaks.